COURSE OVERVIEW:

The meaning of Non-Destructive Testing (NDT) within a refinery context encompasses a broad range of analytical techniques used to evaluate the properties of materials, components, or systems without causing damage. In the high-stakes environment of a refinery, NDT serves as the primary diagnostic tool for ensuring that pressure vessels, heat exchangers, and storage tanks maintain their structural integrity throughout their operational life. By utilizing advanced physics-based methods, inspectors can detect subsurface flaws, measure wall thinning, and identify metallurgical changes that could lead to catastrophic failure if left unaddressed.

The scope of this course is designed to bridge the gap between theoretical NDT principles and the practical realities of refinery maintenance and shutdown schedules. Participants will explore the limitations and advantages of various methods, ranging from conventional Radiography and Ultrasonics to advanced techniques like Phased Array and Eddy Current Testing. The training emphasizes the selection of the most appropriate method based on the specific degradation mechanism suspected, such as high-temperature hydrogen attack or stress corrosion cracking. Furthermore, the course addresses the regulatory frameworks and international standards that govern refinery inspections globally.

The coverage of the program includes a deep dive into the 10 core modules of refinery inspection, starting with the fundamental physics of wave propagation and electromagnetic fields. It moves through the specific applications of NDT in inspecting welded joints, furnace tubes, and complex piping geometries common in distillation units. Detailed modules are dedicated to data interpretation, the integration of NDT results into Risk-Based Inspection (RBI) programs, and the emerging role of digital radiography and automated ultrasonic testing. The course concludes with a focus on reporting accuracy and the ethical responsibilities of the NDT practitioner in a high-risk industrial setting.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Distinguish between different NDT methods based on refinery-specific damage mechanisms.
• Interpret ultrasonic signals to accurately size internal flaws in pressure vessel walls.
• Evaluate the effectiveness of Radiographic Testing versus Digital Radiography for weld quality.
• Apply Magnetic Particle Testing and Liquid Penetrant Testing for surface crack detection.
• Analyze the principles of Eddy Current Testing for heat exchanger tube inspections.
• Understand the integration of NDT data into API 510 and API 570 inspection programs.
• Identify the early signs of High-Temperature Hydrogen Attack (HTHA) using advanced NDT.
• Perform basic calculations for radiation safety and ultrasonic beam spread.
• Assess the reliability of automated ultrasonic testing (AUT) for corrosion mapping.
• Formulate a comprehensive NDT inspection plan for a major refinery turnaround.
• Verify the qualifications and certifications of NDT personnel according to ASNT standards.
• Prepare detailed inspection reports that facilitate informed fitness-for-service decisions.

TARGET AUDIENCE:

This course is intended for Refinery Inspection Engineers, NDT Technicians, Quality Assurance and Quality Control (QA/QC) Personnel, Maintenance Engineers, Reliability Engineers, and Plant Integrity Managers who are responsible for the safety and longevity of refinery assets.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.